Work areas that are compact, but not cramped, not only promote efficient motion, but also improve scheduling accuracy by allowing a more precisely predictable determination of a job’s total cycle time. This total cycle time is not just the time a machine is producing chips; it takes into account all factors involved in part production, such as setups, inspection, secondary operations and so on.

2. 5S Organization This idea of a more predictable motion is also a function of 5S organizational principles, which are direct extensions of the visual factory theme and staples of any lean push. Just what the 5S’s stand for can differ from shop to shop (they typically represent sort, shine, simplify, standardize and sustain).
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3. Setup Photos – Each time a new job is set up, R&D takes photos of the fixtures, tools – anything that will be helpful in setting up the job again so there is no wheel-reinvention the next time that job comes through the shop. These photos, along with standardized work sheets, are included in each manila job folder.

Culture shock is one of the biggest obstacles to implementing lean manufacturing into an existing shop. Getting experienced shop workers to adopt a lean waste-ridding mindset often isn’t the easiest thing to do.